Pre-Cured Edge Seal

ABSTRACT

The different illustrative embodiments provide a method and apparatus for installing an edge seal. In one illustrative example, a pre-cured edge seal is placed on an edge of a composite structure with a sealant to form a placed pre-cured edge seal. The placed pre-cured edge seal is then cured on the composite structure. 
     In another illustrative embodiment, an edge of a structure is prepared with solvent, and a brush coat of sealant is applied to the top and the edge of the structure. A fillet is applied to the base of the edge of the structure. A pre-cured edge seal is applied to the edge of the structure, and the edge is cured.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to composite components and inparticular to a method and apparatus for manufacturing compositecomponents. Still more particularly, the present disclosure relates to amethod and apparatus for improving the method of edge sealing.

2. Background

Aircraft are being designed and manufactured with greater and greaterpercentages of composite materials. Some aircraft may have more thanfifty percent of its primary structure made from composite materials.Composite materials may be used in aircraft to decrease the weight ofthe aircraft. This decreased weight may improve payload capacities andfuel efficiencies. Further, composite materials may provide longerservice life for various components in an aircraft.

Composite materials may be tough, light-weight materials, created bycombining two or more dissimilar components. For example, a compositemay include fibers and resins. The fibers and resins may be combined toform a cured composite material.

Composite materials may be used in various portions of an aircraft.These portions include, for example, skin panels, stringers, shear-ties,ribs, fuselage sections, and other suitable components. In manufacturingcomposite components, it may be desirable to seal the compositecomponent edges. For example, a sealant may be applied to an edge of thecomposite component such as, for example, an edge of an internalstructure within a wing. The sealant may be used to protect thecomposite part from the environment. The sealant may keep moisture outof an area on which the sealant is applied. The sealant may also be usedto contain electro magnetic currents running through the fibers of acomposite structure as a result of lightning strike events or staticbuild-up.

SUMMARY

The different illustrative embodiments provide a method and apparatusfor installing an edge seal. In one illustrative example, a pre-curededge seal is placed on an edge of a composite structure with a sealantto form a placed pre-cured edge seal. The placed pre-cured edge seal isthen cured on the composite structure.

In another illustrative embodiment, an edge of a structure is preparedwith solvent, and a brush coat of sealant is applied to the top and theedge of the structure. A fillet is applied to the base of the edge ofthe structure. A pre-cured edge seal is applied to the edge of thestructure, and the edge is cured.

In yet another illustrative embodiment, a mold is identified for anumber of dimensions of the pre-cured edge seal. The mold is filled withsealant. The sealant is cured to form the pre-cured edge seal with thenumber of dimensions.

In yet another illustrative embodiment, a sealant is partially cured toform a pre-cured edge seal. The pre-cured edge seal is extruded into anumber of shapes and dimensions, and then fully cured.

The features, functions, and advantages can be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the advantageousembodiments are set forth in the appended claims. The advantageousembodiments, however, as well as a preferred mode of use, furtherobjectives and advantages thereof, will best be understood by referenceto the following detailed description of an advantageous embodiment ofthe present disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a flow diagram of aircraft production and service methodologyin accordance with an advantageous embodiment;

FIG. 2 is a block diagram of an aircraft in accordance with anadvantageous embodiment;

FIG. 3 is a block diagram of an aircraft in accordance with anadvantageous embodiment;

FIG. 4 is an illustration of an aircraft in accordance with anadvantageous embodiment;

FIG. 5 is an illustration of a portion of a wing in accordance with anadvantageous embodiment;

FIG. 6 is an illustration of a portion of an internal wing structure inaccordance with an advantageous embodiment;

FIG. 7 is an illustration of a pre-cured edge seal applied to the edgeof a structure in accordance with an advantageous embodiment;

FIG. 8 is an illustration of a cross-section of a pre-cured edge sealapplied to the edge of a structure in accordance with an advantageousembodiment;

FIG. 9 is a flowchart illustrating a process for applying a pre-curededge seal in accordance with an advantageous embodiment;

FIG. 10 is a flowchart illustrating a process for manufacturing apre-cured edge seal in accordance with an advantageous embodiment; and

FIG. 11 is a flowchart illustrating a process for manufacturingpre-cured edge seal material in accordance with an advantageousembodiment.

DETAILED DESCRIPTION

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 100 as shown in FIG. 1 and an aircraft 200 as shownin FIG. 2. During pre-production, exemplary method 100 may includespecification and design 102 of the aircraft 200 and materialprocurement 104. During production, component and subassemblymanufacturing 106 and system integration 108 of the aircraft 200 takesplace. Thereafter, the aircraft 200 may go through certification anddelivery 110 in order to be placed in service 112. While in service by acustomer, the aircraft 200 is scheduled for routine maintenance andservice 114 (which may also include modification, reconfiguration,refurbishment, and so on).

Each of the processes of method 100 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof vendors, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 2, the aircraft 200 produced by exemplary method 100may include an airframe 202 with a plurality of systems 206 and aninterior 208. Examples of high-level systems 206 include one or more ofa propulsion system 210, an electrical system 212, a hydraulic system214, an environmental system 216, and a fuel system 218. Any number ofother systems may be included. Although an aerospace example is shown,the principles of the disclosure may be applied to other industries,such as the automotive industry, marine industry, space industry, andother industries.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 100. Forexample, components or subassemblies corresponding to production process106 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 200 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 106 and 108, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 200. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft200 is in service, for example and without limitation, to maintenanceand service 114.

The different illustrative embodiments recognize that some compositematerials exhibit a unique characteristic called edge glow when thestructure or adjacent structure has a high current attached to thestructure. Edge glow results from the current being routed through thefibers of the composite material, which causes the edge of the structureto glow. This condition forms light at a cut edge of the compositestructure. Where a composite structure is exposed to fuel and fuelvapor, such as a composite structure internal to the wing, edge glowbecomes critical requiring protection of the edge of the compositestructure.

The different illustrative embodiments recognize that current methods ofedge sealing for internal composite structures involve difficult andtime consuming processes. Current methods involve the use of wet sealantthat is difficult to apply, slumps after application, shrinks whencured, and is time consuming to install due to the sealant slumprequiring the sealant to be reapplied to meet the minimum dimensionrequirements.

Therefore, the different illustrative embodiments provide a method andapparatus for improving edge sealing. In particular, these differentadvantageous embodiments may control, reduce, or minimize time andmaterials needed to install an edge seal.

In one illustrative example, an edge of a structure is prepared withsolvent, and a brush coat of sealant is applied to the top and the edgeof the structure, as well as to the base of the structure. A fillet isinserted at the base of the edge of the structure. A pre-cured edge sealis applied to the edge of the structure, and the edge is cured.

In these examples, a pre-cured edge seal may be fully cured and formedinto the required dimensions with the use of a mold, or may be partiallycured and then extruded before being fully cured. As a result, theillustrative embodiments improve the installation of the edge seal bydecreasing the installation time, eliminating excessive sealant, andassuring the correct dimensions of the edge seal.

With reference now to FIG. 3, a block diagram of a sealing system isdepicted in accordance with an advantageous embodiment. Sealing system300 is an example in which a method and apparatus for manufacturing andinstalling a pre-cured edge seal may be implemented.

In this illustrative embodiment, sealing system 300 has edge seal mold302 and edge seal extrusion system 304. Pre-cured edge seal 306 may bemanufactured using either of edge seal mold 302 or edge seal extrusionsystem 304. In an illustrative embodiment, sealant may be inserted intoedge seal mold 302 and fully cured to form pre-cured edge seal 306. Inanother illustrative embodiment, sealant may be inserted into edge sealextrusion system 304 and partially cured to form pre-cured edge seal 306that may be extruded and fully cured. A sealant may be any type ofviscous material that may change states to become solid once applied. Asealant is used to prevent the penetration of various materials such as,for example, without limitation, air, gas, noise, liquid, or some othermaterial.

Structure 308 is a component of a vehicle, such as, without limitation,an aircraft, a submarine, a spacecraft, a surface ship, and othersuitable vehicle. Structure 308 may be, for example, a component of afuel tank, hydraulic system, or some other system exposed to humidity,moisture, light, electrical currents, or vapors. Pre-cured edge seal 306may be applied to the surface, and in particular the edge of thesurface, of structure 308. Pre-cured edge seal 306 may be, for example,without limitation, an acryl sealant, polysulfide sealant, polyurethanesealant, silicone sealant, WKT sealant, firestop, or some other suitablematerial. Fillet 310 may be used to fill any gap left between structure308 and pre-cured edge seal 306. Fillet 310 is a sealant applied in itsun-cured, or wet, form to the base of the edge of structure 308. Fillet310 may be any type of viscous material that changes state to becomesolid and is appropriate for the edge of the structure being sealed,such as, without limitation, acryl sealant, polysulfide sealant,polyurethane sealant, silicone sealant, WKT sealant, firestop, or someother suitable material.

The different components illustrated for sealing system 300 in FIG. 3are not meant to provide architectural limitations to the manner inwhich different embodiments may be implemented. The differentillustrative embodiments may be implemented in a sealing systemincluding components in addition to or in place of those illustrated forsealing system 300. Other components shown in FIG. 3 can be varied fromthe illustrative examples shown.

With reference now to FIG. 4, an illustration of an aircraft is depictedin accordance with an advantageous embodiment. Aircraft 400 is anexample of a vehicle in which a method and apparatus for installing apre-cured edge seal may be implemented. In this illustrative embodiment,aircraft 400 has wings 402 and 404 attached to body 406. Aircraft 400includes wing mounted engine 408, wing mounted engine 410, and tail 412.

In particular, the different advantageous embodiments may be used toinstall pre-cured edge seals to structural components in wings 402 and404 and body 406. For example, the different advantageous embodimentsmay be used along the edges of the internal structures, such as spars,stringers, shear-ties, ribs, and other composite structures with cutedges. In one example, wing spar to body joints are used to attach thewing spars for wings 402 and 404 to a structural component in body 406,which may be located at points 414 and 416.

Wing spars are structural components that are used to form wings 402 and404. In particular, ribs are attached to these wing spars and to wingskins. A spar is a main structural member of the wing. A spar runs thelength of the wing and is typically around or about a right angle to thebody or fuselage. Upper and lower wing skins form the aerodynamicsurfaces and are separated by the spars. Together with the spar, ribsand skins form the wing box, which typically carries the majority of theforces of both lift and the weight of the wings when the aircraft is onthe ground. Other structural and forming members such as ribs areattached to a spar.

With reference now to FIG. 5, an illustration of a portion of a wing isdepicted in accordance with an advantageous embodiment. Wing 500 is anexample of wing 404 in FIG. 4.

In these illustrative examples, wing skin 502 represents the bottomportion of a wing. Forward wing spar 504 and aft wing spar 506 separatewing skin 502 and the top portion of the wing skin not depicted in thisillustration. Forward wing spar 504 and aft wing spar 506 are separatedby ribs 508 and 510. Forward wing spar 504, aft wing spar 506, rib 508,and rib 510 are examples of internal structures that may require edgesealing. Other internal structures may include, without limitation,stringers, shear-ties, and other composite components. Forward wing spar504, aft wing spar 506, ribs 508, rib 510, and wing skin 502 may beformed from different materials. For example, aluminum, titanium, orcomposite materials may be used. Composite materials may include, forexample, graphite combined with epoxy resin, titanium, and othergraphite composites. Carbon fiber reinforced polymer (CFRP) is anotherexample of a composite that may be used.

With reference now to FIG. 6, an illustration of a portion of aninternal wing structure is depicted in accordance with an advantageousembodiment. Wing portion 600 is an example forward wing spar 504 in FIG.5.

Wing spar 602 includes bottom flange 604 and top flange 606. Top flange606 and bottom flange 604 represent a sealed edge. Bottom flange 604 ofwing spar 602 is sealed with pre-cured edge seal 608. Fillet 610 isapplied to the base of bottom flange 604 to fill in the gap between thebottom of pre-cured edge seal 608 and bottom flange 604.

With reference now to FIG. 7, an illustration of a pre-cured edge sealapplied to the edge of a structure is depicted in accordance with anadvantageous embodiment. Structure 700 is an example of forward wingspar 504 in FIG. 5 and wing spar 606 in FIG. 6. The pre-cured edge sealmay be applied using sealing system 300 in FIG. 3.

Wing spar 702 is an example of an internal structure of a wing. Wingspar 702 may be comprised of composite materials including fibers thatmay conduct electrical currents. Wing spar 702 may be exposed to fuel orfuel vapors within the wing. Wing spar 702 is positioned on wing skin704, and sealed with pre-cured edge seal 706.

Pre-cured edge seal 706 may be manufactured using edge seal mold 302 inFIG. 3, edge seal extrusion system 304 in FIG. 3, and/or with some othersuitable system. A sealant may be any type of viscous material that maychange states to become solid. A sealant is used to prevent thepenetration of various materials such as, for example, withoutlimitation, air, gas, noise, liquid, or some other material. In thisexample, pre-cured edge seal 706 may provide corrosion resistant and orresistance to various environments, such as, for example, exposure tofuel or fuel vapors. Pre-cured edge seal 706 may be, for example,without limitation, an acryl sealant, polysulfide sealant, polyurethanesealant, silicone sealant, WKT sealant, firestop, or some other suitablematerial.

Pre-cured edge seal 706 is manufactured in the required dimensions tofit a variety of wing spar thicknesses, that may be adjusted furtherwith the application of additional fillet seal. The required dimensionsmay be, for example, a degree of thickness, a shape, a degree offlexibility, and the like.

Fillet 708 is a sealant applied in its un-cured, or wet, form to thebase of the edge of wing spar 702, where wing spar 702 meets wing skin704, to fill in any gap left between pre-cured edge seal 706 and wingskin 704. Fillet 708 may be any type of viscous material that changesstate to become solid and is appropriate for the edge of the structurebeing sealed, such as, without limitation, acryl sealant, polysulfidesealant, polyurethane sealant, silicone sealant, WKT sealant, firestop,or some other suitable material. Fillet 708 may be the same type ofsealant used to manufacture pre-cured edge seal 706, or may be adifferent type of sealant. Fillet 708 fills any gap that may remain oncepre-cured edge seal 706 is applied to the edge of wing spar 702.

Once fillet 708 and pre-cured edge seal 706 have been applied, a finalcuring process may occur to bond pre-cured edge seal 706 to fillet 708and wing spar 702, and finish the edge sealing process. Curing refers tothe process of toughening or hardening a viscous material into a solidstate. Curing may be brought about by chemical additives, a reaction towater or heat, or by exposure to ambient or elevated temperature per theseal material requirements.

With reference now to FIG. 8, an illustration of a cross-section of apre-cured edge seal applied to the edge of a structure is depicted inaccordance with an advantageous embodiment. Cross-section 800 is anexample of a cross-section of a portion of a structure sealed with apre-cured edge seal, such as the portion represented by line A in FIG.7.

Spar 802 is positioned against wing skin 804. Spar 802 is an example ofspar 702 in FIG. 7. Spar 802 is sealed with pre-cured edge seal 806.Fillet 808 is applied to the base of spar 802 and pre-cured edge seal806.

With reference now to FIG. 9, a flowchart illustrating a process forapplying a pre-cured edge seal is depicted in accordance with anadvantageous embodiment. This process may be implemented duringcomponent and subassembly manufacturing 106 and maintenance and service114 of production and services method 100 in FIG. 1, and in sealingsystem 300 in FIG. 3. The process begins by preparing an edge of astructure using a solvent (step 902). The solvent may be any type ofcleaner or solvent used to clean and/or remove sealant from a structure,such, for example, methyl polyketone (MPK) solvents. The processinspects the preparation (step 904) to ensure the area is ready for anedge seal. The process then applies a brush coat of sealant along thetop and edge of a structure (step 906). In another illustrativeembodiment, a brush coat of sealant may be applied to the pre-cured edgeseal before the edge seal is applied to the structure. The brush coat ofsealant is an application of sealant in its un-cured, or wet, form. Thesealant may be any type of viscous material that changes state to becomesolid and is appropriate for the edge of the structure being sealed,such as, without limitation, acryl sealant, polysulfide sealant,polyurethane sealant, silicone sealant, WKT sealant, firestop, or othersuitable material.

Next, the process applies a fillet of sealant at the base of the edge ofthe structure (step 908). The sealant may be the same type of sealantused for the brush coat and to manufacture the pre-cured edge seal, ormay be a different type of sealant. The process then applies a pre-curededge seal (step 910) to the edge of the structure, such as the edge ofwing spar 702 in FIG. 7. The prior brush coat application of sealantacts as a bonding agent for the pre-cured edge seal and the structure.The process then cleans up the application area (step 912) and cures theedge of the structure (step 914). This curing process solidifies thebond created by the brush coat of sealant between the pre-cured edgeseal and the structure. The process then inspects the seal and cure(step 916), with the process terminating thereafter.

Current methods involve more time and additional steps to achieve anedge seal. For example, the area is prepared and cleaned using asolvent, the preparation is inspected to ensure the area is ready for aseal, and a brush coat of sealant is applied. These steps takeapproximately five minutes, similar to the first few steps in theillustrative embodiment, which also take about five minutes. However,after these steps, current methods next apply a first application ofsealant as both a fillet and edge seal, which takes approximatelyfifteen minutes. That application must then be cured, takingapproximately another ten minutes, before a second application ofsealant to both the fillet and edge seal areas can be applied. Thesecond application of sealant takes approximately another ten minutes,and is required in order to achieve the required dimensions ofthickness. Due to multiple applications of sealant being applied, moresealant is used than may be necessary to achieve the desired degree ofthickness. This is in part due to the shrinkage and slumping of sealantduring the curing process, and in part due to the lack of tools formeasuring the thickness of an edge seal once it is applied to astructure. As a result, excessive sealant is used to achieve a minimumdegree of required thickness. This leads to more cleanup, excessivehazardous waste, and additional time. Cleanup in current methods maytake approximately ten minutes, before the final cure to solidify thesecond application. All together, the time expended on the steps of thecurrent method for edge sealing total forty-five minutes or more.

In the illustrative embodiments, once the brush coat of sealant isapplied, the pre-cured edge strip is applied to the structure, takinglittle time as compared to current processes. In these examples the timemay be approximately five minutes. A small fillet is applied to the baseof the seal, taking approximately another five minutes. This process ismore efficient because the only sealant applied in wet form is the brushcoat and the fillet. The majority of the seal, which makes of the bulkof the sealant used, is pre-cured and in a solid, yet flexible, statethat makes it easier to apply.

Additionally, the pre-cured edge seal requires less clean up time, againdue to the minimum amount of wet sealant being applied to the structure,and cleanup in the illustrative embodiments can take approximately fiveminutes, as compared to the current methods which require ten minutes ormore.

Thus, the illustrative embodiments provide a method that allows forefficient edge sealing in approximately twenty minutes, half the time ofcurrent methods. In addition to the more efficient time frame, theillustrative embodiments provide a method that eliminates excessivehazardous waste, and reduces the weight of the edge seal by minimizingthe dimensions to the exact requirements.

With reference now to FIG. 10, a flowchart illustrating a process formanufacturing a pre-cured edge seal is depicted in accordance with anadvantageous embodiment. This process may be implemented duringcomponent and subassembly manufacturing 106 and maintenance and service114 of production and services method 100 in FIG. 1, and in sealingsystem 300 in FIG. 3.

A number, as used herein, refers to one or more items. The processbegins by identifying a mold for a number of dimensions of a pre-curededge seal (step 1002). The dimensions may be, for example, withoutlimitation, a degree of thickness, a shape, a degree of flexibility, oranother suitable dimension requirement. In an illustrative embodiment,common dimensions for the pre-cured edge seal may be, withoutlimitation, a dome height of 0.10 inches, a thickness of leg 0.10inches, and a length of leg 0.20. Dome height refers to the dome shapeof the edge seal as it overlaps the edge of the structure, such as, forexample, the flange of a wing spar. The process fills the mold withsealant (step 1004). The sealant may be any type of viscous materialthat changes state to become solid and is appropriate for the edge ofthe structure being sealed, such as, without limitation, acryl sealant,polysulfide sealant, polyurethane sealant, silicone sealant, WKTsealant, firestop, or other suitable material.

The process then fully cures the sealant to form a pre-cured edge seal(step 1006) in the number of dimensions for the structure to which theedge seal will be applied. The pre-cured edge seal is still flexiblealthough in a solid state, and can be glued onto the edge of a structureusing a brush coat of wet sealant to adhere the pre-cured edge seal tothe edge of the structure. A final curing process will bond thepre-cured edge seal to the edge of the structure by curing theapplication of wet sealant used as a bonding agent. Then the processstores the pre-cured edge seal on a roll or package (step 1008), withthe process terminating thereafter. In an illustrative embodiment, aroll on which the pre-cured edge seal may be stored is large enough indiameter to prevent the seal from kinking or twisting. In anotherillustrative embodiment, a package in which the pre-cured edge seal maybe stored is a flat package similar to a plastic bag.

With reference now to FIG. 11, a flowchart illustrating a process formanufacturing pre-cured edge seal material is depicted in accordancewith an advantageous embodiment. This process may be implemented duringcomponent and subassembly manufacturing 106 and maintenance and service114 of production and services method 100 in FIG. 1, and in sealingsystem 300 in FIG. 3.

The process begins by partially curing a sealant to form a pre-curededge seal (step 1102). Partially curing a sealant may be performed byusing a curing process, such as chemical additives, water, heat, orexposure to ambient temperature, to bring the sealant from its viscousstate to a partially cured state, dependent upon material requirements,without letting the curing process complete. The partially cured edgeseal will not be in a fully cured state, but will still be in a wet orsemi-solid state and solid enough to extrude into a shape. The processthen extrudes the pre-cured edge seal into a shape (step 1004). Theshape may be, for example, a shape in the required dimensions for theedge of a particular structure. The process then cures the seal (step1006), and stores the pre-cured edge seal as a roll or package (step1108), with the process terminating thereafter. The roll, which is largeenough in diameter to prevent the pre-cured edge seal from kinking ortwisting, or the flat package like a plastic bag may be a type ofhousing that stores the pre-cured edge seal until it is ready to beapplied to a structure.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatus, methods and computer programproducts. In this regard, each block in the flowchart or block diagramsmay represent a module, segment, or portion of a process for installingand edge seal. In some alternative implementations, the function orfunctions noted in the block may occur out of the order noted in thefigures. For example, in some cases, two blocks shown in succession maybe executed substantially concurrently, or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved.

Therefore, the different illustrative embodiments provide a method andapparatus for improving edge sealing. In particular, these differentadvantageous embodiments may control, reduce, or minimize time andmaterials needed to install an edge seal.

In one illustrative example, an edge of a structure is prepared withsolvent, and a brush coat of sealant is applied to the top and the edgeof the structure. A fillet is inserted at the base of the edge of thestructure. A pre-cured edge seal is applied to the edge of thestructure, and the edge seal is cured.

In these examples, when cured, the pre-cured edge seal may be formedinto the required dimensions with the use of a mold. In anotherillustrative example, sealant may be partially cured into pre-cured edgeseal material and then extruded into shape before being fully cured. Asa result, the illustrative embodiments improve the installation of theedge seal by decreasing the installation time, eliminating excessivesealant, and assuring the correct dimensions of the edge seal.

The illustrative embodiments eliminate the need to apply a secondapplication of fillet or edge seal, and provide for a more efficientmethod of installing the edge seal by brush coating the surface and theninstalling the pre-cured edge seal. The illustrative embodiments providea method for installing a pre-cured edge seal that greatly reduces thewaste of excess sealant, thereby reducing the weight of the vehicle,decreasing hazardous waste, and reducing cleanup time required toinstall the edge seal.

The description of the different advantageous embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Although the different advantageousembodiments in the illustrative examples are describe with respect to anaircraft, one or more the different advantageous embodiments may beapplied to other vehicles other than aircraft, such as, for example,without limitation, a submarine, a spacecraft, a surface ship, and othersuitable vehicles. Further, different advantageous embodiments mayprovide different advantages as compared to other advantageousembodiments. The embodiment or embodiments selected are chosen anddescribed in order to best explain the principles of the embodiments,the practical application, and to enable others of ordinary skill in theart to understand the disclosure for various embodiments with variousmodifications as are suited to the particular use contemplated.

1. A method for installing an edge seal, the method comprising: placinga pre-cured edge seal on an edge of a composite structure with a sealantto form a placed pre-cured edge seal; and curing the placed pre-curededge seal on the composite structure.
 2. The method of claim 1, furthercomprising: applying a layer of the sealant to the base of the compositestructure to form a fillet.
 3. The method of claim 1, wherein placingthe pre-cured edge seal on the edge of the composite structure with thesealant further comprises: applying a brush coat of the sealant to thecomposite structure; and placing the pre-cured edge seal on the edge ofthe composite structure, wherein the brush coat of the sealant adheresthe pre-cured edge seal to the composite structure.
 4. The method ofclaim 1, wherein the composite structure is selected from one of anaircraft structure, a wing spar, a stringer, a shear-tie, and a rib. 5.An apparatus comprising: a structure having an edge, a top, and a base;a pre-cured edge seal having a first end and a second end attached onthe edge of the structure; a sealant located between the pre-cured edgeseal and the structure, wherein the sealant attaches the pre-cured edgeseal to the edge of the structure; and a fillet located at the base ofthe structure.
 6. The apparatus of claim 5, wherein the first end of thepre-cured edge seal forms a curved shape at the top of the structure,wherein the curved shape comes over the top of the structure to form ahook shape.
 7. The apparatus of claim 5, wherein the second end of thepre-cured edge seal forms a straight edge.
 8. A method for installing anedge seal, the method comprising: preparing an edge of a structure usinga solvent; applying a brush coat of a sealant along a top and the edgeof the structure; applying a fillet of the sealant at a base of the edgeof the structure; applying a pre-cured edge seal; and curing the edge ofthe structure.
 9. The method of claim 8, wherein the structure isselected from one of an aircraft structure, a wing spar, a stringer, ashear-tie, and a rib.
 10. The method of claim 8, wherein the brush coatof the sealant is an application of a thin layer of the sealant in a wetstate.
 11. The method of claim 8, wherein the application of the filletof the sealant is an application of the sealant in a wet state.
 12. Themethod of claim 8, wherein the application of the pre-cured edge seal isan application of the sealant in a fully cured state.
 13. The method ofclaim 8, wherein the pre-cured edge seal is formed in accordance with anumber of dimensions.
 14. The method of claim 8, wherein the applicationof the pre-cured edge seal is an application of the sealant in apartially cured state.
 15. A method for manufacturing a pre-cured edgeseal, the method comprising: identifying a mold for a number ofdimensions of the pre-cured edge seal; filling the mold with sealant;and curing the sealant to form the pre-cured edge seal with the numberof dimensions.
 16. The method of 15, wherein the number of dimensionsinclude at least one of a degree of thickness, a shape, and a degree offlexibility.
 17. The method of claim 15, wherein the pre-cured edge sealis capable of sealing a structure selected from one of an aircraftstructure, a wing spar, a stringer, a shear-tie, and a rib.
 18. A methodfor manufacturing a pre-cured edge seal, the method comprising:partially curing a sealant to form the pre-cured edge seal; extrudingthe pre-cured edge seal into a number of shapes and dimensions.
 19. Themethod of claim 18, wherein partially curing the sealant furthercomprises: applying a curing process to the sealant; and stopping thecuring process before the sealant is fully cured to form the pre-curededge seal, wherein the pre-cured edge seal is the sealant in a partiallycured state.
 20. The method of claim 18, wherein the pre-cured edge sealis capable of sealing a structure selected from one of an aircraftstructure, a wing spar, a stringer, a shear-tie, and a rib.